Digital Twin of an Aluminum Foam

Analysis of the pore space of an open-cell aluminum foam, modeling of a digital twin based on the pore sizes, and determination of various properties.

Open-cell metallic materials, such as foams or lattice structures, are largely defined by the morphology of their pore space. An analysis of this pore space is therefore of great importance. Instead of conducting complex experiments, this can also be carried out in a 100% digital workflow in GeoDict. The basis for the three-dimensional foam model is a CT scan which was imported into GeoDict followed by segmentation. The pore space was analyzed, subsequently. Finally, the result was used to create a statistical digital twin of the foam.

This fully parametrized digital twin was then used for a digital parameter study. This allowed analyzing the influence of strut diameter on the following properties:

  • permeability
  • electrical conductivity
  • stiffness

This workflow can be used for materials produced by a variety of manufacturing processes:

  • Laser sintering
  • Casting
  • Foaming
  • Coating PU foams with metals

What does this mean for you as a customer?

  •  You can analyze your open cell metallic materials in GeoDict
  •  You can digitally develop your material without the need to produce all variants.
  •  GeoDict opens up completely new possibilities for material development as well as a significant reduction in development time

Authors and application specialists

Dr.-Ing. Martina Hümbert

Senior Business Manager
for Digital Materials R&D

Andreas Grießer, M.Sc.

Senior Business Manager
for Image Processing and Image Analysis

Dr.-Ing. Oliver Rimmel

Business Manager
for Digital Materials R&D

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Part 1: Image processing and analysis

Approach

First, the scan of an open cell aluminum foam was imported into GeoDict and segmentation was conducted. Subsequently, the pores were identified in GeoDict's PoroDict module using a watershed algorithm. This identification works very well, despite the cells of the foam samples being quite open. Only pores that do not intersect with the domain boundary were analyzed, since pores that are cut off at the boundary would distort the results.

The following modules were used:

Part 2: Creation of a statistical digital twin

Approach

Based on the previously determined pore size distribution of the scan, a statistical digital twin of the foam was created. For this purpose, the pore size distribution and the pore content were specified in the FoamGeo module. The statistical digital twin is not identical to the model generated from the scan, but has the same statistical properties. For validation purposes, pore size distribution and permeability of the scan and twin were then compared.

The following modules were used:

Comparison of scan and statistical digital twin

Part 3: Digital parameter study

Approach

Based on the previously determined pore size distribution of the scan, a statistical digital twin of the foam was created. For this purpose, the pore size distribution and the pore content were specified in FoamGeo. The pore size distribution was to remain constant, while the pore content was varied (solid volume fraction (SVF) of 10%, 13%, 17%, 20%). The statistical digital twin is not identical to the model generated from the scan, but has the same statistical properties. For comparison, the pore size distribution and the permeability of the scan and the twin were compared.

Comparison of statistical digital twin and scan

Additional information

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